System for enabling arc welders

ABSTRACT

A system for enabling an electric arc welder adapted to perform various welding processes using weld parameters and a welding wire. The system comprises a first receptacle for a first memory button having a chip loaded with digital data indicative of a specific welding procedure specification constituting a set of at least weld parameters, a specific weld process, electrical characteristics, and selected welding wire features; a second receptacle for a second memory button having a chip loaded with digital data indicative of recorded features of welding wire loaded onto the welder; and, a disable circuit to disable the welder to process the specific welding procedure when the data indicative of recorded features of the welding wire fails to correspond with the data indicative of the selected welding wire features.

The present patent application is a continuation of U.S. patentapplication Ser. No. 09/866,360 filed May 29, 2001 now U.S. Pat. No.6,552,303.

The invention relates to the art of electric arc welding and moreparticularly to a system for loading an electric arc welder with awelding procedure specification and then enabling the welder whenconditions are proper to execute the selected welding procedurespecification WPS.

INCORPORATION BY REFERENCE

In the welding industry, the welding of critical applications involvesexperimental optimization of many parameters and weld controllingfactors into an acceptable weld procedure. This procedure is generallyreferred to as the welding procedure specification (WPS) which is wellknown in the art of electric arc welding and is generally described in a1997 article by D. K. Miller entitled What Every Engineer Should Knowabout Welding Procedures. A reprint of this article is incorporated byreference herein to describe the general content and application of aWPYS so this material need not be repeated. Bloch U.S. Pat. No.5,708,253 suggests the concept of loading the welding procedurespecification into the controller of an electric arc welder and thenmodifying the various parameters. The data causes a central controlmicroprocessor to implement the parameters during a welding operation.This fixed programmed use of welding procedures is known. The Blochpatent is incorporated by reference to illustrate backgroundinformation. In the present invention, data is introduced into thecontrol logic network by memory chips of the type available from DallasSemiconductor Corporation of Dallas, Tex., under the trademark “TouchMemory.” These electronic memory buttons store digital data in aninternal READ/WRITE chip which data is transmitted upon command from thebutton to an interface communicated with said control logic network. Inthe present invention, the interface is communicated with the button byway of a receiving receptacle. Any of many known button receivingreceptacles can be used. One receptacle is disclosed in Scholder U.S.Pat. No. 5,862,071, which patent is incorporated by reference to showone of many memory chip receptacles.

Assignor has a pending U.S. application Ser. No. 336,574 filed on Jun.21, 1999 and disclosing the concept of memory chips for receiving dataand transmitting data to the controller of an electric arc welder bytouching of the support structure for the chip. This prior applicationis incorporated by reference herein as further background informationregarding the technique of employing touch interrogated memory chips forreceiving and transmitting data from and to the digital processingcontroller of an electric arc welder.

BACKGROUND OF INVENTION

In electric arc welding as described in Bloch U.S. Pat. No. 5,708,253,repeatable quality in electric arc welding for specific applicationsrequires that the procedure used in the welding process be the same orwithin certain constraints. In addition, the weldor or operator assignedto execute the procedure must be qualified to perform the specificwelding operation by a prior testing and prior actual experience.Furthermore, even a weldor qualified for a specific procedure can losethe specific skill required after long periods without actuallyperforming the welding operation. Consequently, qualification of theoperator should be assured so the welding operation can meet thestandard necessary for acceptance of the welding result. In addition, itis necessary that the parameters involved in the welding procedurespecification be met during the welding operation. In the past, thewelding procedure was manually loaded into the digital processcontroller of the electric arc welder by various interfaces connected tothe controller. In addition, items of the WPS, such as wire feed speed,wire specification, shielding gas, preheat, impass heat, post heat,etc., were set according to written or stored criteria constituting thewelding procedure specification. Implementing this technique, togetherwith assuring qualification of the operator presented difficulties. Thewelding by the weldor was performed irrespective of compliance with thevarious parameters constituting the welding procedure specification andirrespective of the actual qualification of the weldor performing thewelding operation. Consequently, detailed record keeping and checking ofthe various parameters preparatory to the welding operation werenecessary, but quite complex. When it was determined that the weldingprocedure was not followed or the operator was not adequately qualified,the resulting welding operation was rejected or required subsequentremedial processing. Consequently, a procedure to assure proper weldingto a detailed specification was complicated and expensive. It required asubstantial amount of record keeping and historical maintenance of dataassociated with the many welds performed in the field.

Goldblatt U.S. Pat. No. 5,500,512 and Bobeczko U.S. Pat. No. 5,553,810disclose bar codes on a wire reel to be read when the reel is loadedonto a welder. A process sheet is also read by a bar code to correlatewith the wire. These patents are incorporated by reference as backgroundtechnology.

THE INVENTION

In electric arc welding, specific applications often involve a weldingprocedure specification WPS that must be followed for acceptance of theweld. In practice, the WPS for a specific application provides thenecessary information to set the electric arc welder and load theelectric arc welder with external constituents for the purposes ofperforming the specified welding process. In accordance with the presentinvention, the WPS for a given welding operation is converted to digitaldata and stored either in a IC chip of a memory button or in a remotelocation such as a computer connected to the welder by an ethernetnetwork. Such network is local or by the internet. WPS is directed tothe controller of the electric arc welder. In the preferred embodimentof the invention the digital data comprising the WPS of a specificwelding operation is loaded into the IC chip of a memory button. As analternative, the memory button includes a code which will allow thedigital data defining the WPS to be directed to the digital processcontroller of the welder. This can be from a memory or from an ethernetnetwork. Thus, the present invention involves a memory button containinga specific digital data defining WPS or a code identifying a specificWPS. As an alternative, the digital data defining the WPS is loadeddirectly into the controller from an external source, such as anethernet network.

In the preferred implementation, a memory button is connected toreceptacle in a touch connector coupled to the controller of the welder.Consequently, by merely placing the memory button into a receptacle onthe touch connector associated with a specific welder, the weldingprocedure to be performed by the welder is directed by process logic tothe controller of the welder. The controller upon receiving the selectedprocedure is disabled unless the various items of the WPS are availableon the welder or used by the welder. To assure the proper wire, gas, andoperator, the touch connector includes additional receptacles for memorybuttons, each of which contain an IC chip loaded with the necessary dataassociated with a particular aspect of the welding process. In practice,the WPS memory button is attached to one receptacle of the touchconnector. Another receptacle receives a memory button with a chipcontaining the qualifications of the particular operator destined toperform the welding procedure. If the welding procedure loaded into thecontroller contains qualifications for the person performing theoperation, then the button containing the weldor qualifications allowsactivation of the welder if the person has at least the qualificationsnecessary for performing the specified WPS. In a like manner, anotherreceptacle on the touch connector receives a touch memory button havinga chip loaded with the information on the welding wire or electrode,such as material, specification, diameter, etc. Data contained on thechip of this memory button is compared to the data indicative of thewelding wire or electrode from the memory chip for the WPS to notdisable the welder. In this way, the welding operation is performed withthe proper welding wire or electrode. Another memory button includes achip loaded with the identification of the shielding gas. When this chipis received in a receptacle on the touch connector, the shielding gasconnected to the welder is determined. If the shielding gas is notproper, the welder is disabled. In accordance with implementation of theinvention, the touch connector can have additional receptacles foradditional memory buttons having chips with data corresponding to afeature or item in the welding procedure specification.

By using the present invention, a work order carries a button includingthe data indicative of the parameters of the welding procedurespecification of a specific welding operation. The wire or electrodebundle for the welder carries another memory button which is removedfrom the wire or electrode and placed in a receptacle on the touchconnector. In a like manner, the welding gas carries a button which isdetached and inserted into another receptacle on the touch connector.Likewise, the operator possesses an identification memory button to bemounted in a designated receptacle on the touch connector. If all ofthese buttons in the touch connector conform, then the welder is notdisabled. However, the welder itself must be capable of performing theselected welding operation. Consequently, the controller itself willoutput information of the type of welder to assure that the WPS can beperformed. When all of these items match, the welding process can beperformed. By merely inserting a plurality of buttons indicative ofwelding items, the welder is commissioned for performing a specificwelding operation, which preferably is also inputted by a memory button.

In accordance with the present invention there is provided a system forenabling an electric arc welder adapted to perform various weldingprocesses using weld parameters and a welding wire. The system comprisesa first receptacle for a first memory button having a chip loaded withdigital data indicative of a specific welding procedure specification.The specification comprises a set of at least weld parameters, aspecific weld process, electrical characteristics, and selected weldingwire or electrode features. The procedure dictates the operatingcharacteristics of the welder during the welding process. A secondreceptacle for a second memory button having a chip loaded with digitaldata indicative of recorded feature of the wire or electrode to be usedby the welder. The system includes a disabled circuit or logic todisable the welder to process the specific welding procedure when thedata indicative of the features of the welding wire fail to correspondwith the data indicative of the selected welding wire or electrodefeatures. Thus, if the desired wire or electrode identified by thesecond button is not the proper wire or electrode for the weldingprocedure, the welder will not be enabled.

In accordance with another aspect of the invention, the electricalcharacteristics or other aspects of the welding procedure specificationrelating to the capabilities of the welder will be compared by theprocess logic in or before the controller of the welder to determine ifthe welder is capable of performing the selected welding procedure.Consequently, both a series of individually placed buttons and thecapabilities of the welder are compared with the loaded weldingprocedure specification to allow the execution of the welding process.

In accordance with another aspect of the invention, the first chipassociated with the first memory button includes digital data defining aselected qualification of the operating weldor or operator so a thirdreceptacle can receive a third memory button having a chip loaded withdigital data indicative of the actual welding qualification of a weldor.A disabled circuit disables the welder to process the welding procedurespecification when the actual welding qualification fails to match orexceed the selected qualification. In accordance with this concept, thethird memory button can be a READ/WRITE memory wherein the qualificationinformation is updated according to the specification being processed.The term “weldor” indicates the person conducting the welding processand the term “welder” is the actual apparatus performing the process.

In accordance with another aspect of the present invention there isprovided a system for enabling an electric arc welder adapted to performvarious welding processes using weld parameters and a welding wire. Thesystem comprises a first receptacle for a first memory button having achip loaded with digital data indicative of a specific welding procedurespecification and constituting a set of at least weld parameters, aspecific weld process, electrical characteristics, and selected weldingwire features. A second receptacle for a second memory button having achip loaded with digital data indicative of an item in the set; and, adisable circuit to disable the welder when the data indicative of theitem fails to correspond with the data indicative of the item.

In yet another aspect of the invention, there is provided a system forenabling an electric arc welder adapted to perform various weldingprocesses using weld parameters and a welding wire. The system comprisesa first receptacle for a first memory button having a chip loaded withdigital data indicative of a specific welding procedure specificationand a selected qualification of the operating weldor. A secondreceptacle for a second memory button having a chip loaded with digitaldata indicative of the actual qualifications of a specific weldor oroperator and a disable circuit to disable the welder to process thespecific welding procedure when data indicative of the actualqualifications fail to match or exceed the selected qualifications.

Still a further aspect of the invention is the provision of a system forenabling an electric arc welder adapted to perform various weldingprocesses using weld parameter and a welding wire or electrode. Thissystem comprises a first receptacle for a first memory button having achip loaded with digital data indicative of a specific welding procedurespecification constituting a set of at least weld parameters, a specificweld process, electrical characteristics and selected welding wirefeatures. This aspect of the invention includes a circuit to load thewelding procedure specification into the controller of the welder to setcharacteristics of the welder. The controller is the digital processingdevice used by welders and can be input logic or another input network.

In accordance with another aspect of the present invention there isprovided a system for controlling an electric arc welder at a weldstation, such as a robot. The system comprises a controller for thepower supply and for external drives at the weld station. These drivesinclude wire feeders and robot drives controlling travel speed duringthe weld, to name a couple. The controller has a digital processingdevice with a section for receiving digital data and for controlling thewelder in compliance with the digital data. In this aspect of theinvention, the data includes a selected value for an external weldcondition, such as arc current or arc voltage of the power supply andwire feed speed and travel speed for the drive units. A data entrystation is used by the operator to select a set level for one of theexternal conditions. A logic network compares the selected level and theselected value to create an action signal based upon this comparison.The digital data is a selected welding procedure specification. In oneaspect, the action signal causes the controller to either decrease orincrease the set level. As an alternative, if the set level is notwithin prescribed limits, the welder is disabled. Thus, an operatorselecting the wrong level for an external condition can cause the welderto be disabled. As a further aspect, the action signal causes theexternal condition to be recorded during the welding operation. Thisresponse to an action signal can be used with other responses. Theaction signal can also merely transmit the selected set level to thepower supply and to the external drive devices, if the set level doesnot deviate beyond a certain amount from the data relating to theexternal condition as contained in the welding procedure specification.In this manner, the external conditions such as wire feed speed, travelspeed, arc current and arc voltage are processed in accordance with thewelding procedure specification, either to set the command signals forthe external condition or to disable the welder from performing thewelding process.

A further aspect of the present invention is the provision of a systemfor controlling an electric arc welder performing a welding operation ata weld station, such as a robot. The system comprises a controller forthe power supply of the welder. The controller has a digital processingdevice with a memory for receiving digital data and a for controllingthe welder in compliance with the digital data. A reading device loadscontrol data containing a specific welding procedure specification intothe memory. The control data includes a selected level for an externalcondition. The controller generates a command signal for the externalcondition. A sensor reads the actual external condition on a real timebasis while a comparison circuit disables the welder when the externalcondition deviates from the selected set level. In this manner, anexternal condition is compared to the selected set condition ascontained in a welding procedure specification and the welder isdisabled when the actual external condition deviates from the level inthe welding procedure specification.

Still a further aspect of the present invention is the provision of amethod for controlling an electric arc welder having a power supply,external drives and a controller for the power supply and drives. Themethod comprises loading digital data containing a specific weldingprocedure specification and including a selected value for an externalcondition. Thereafter, a desired level for an external condition isinputted into the controller and is compared to the value to create acommand signal used by the power supply or external drives. Amodification of this method involves the real time value of the externalcondition and disabling the welder when the real time value deviatesfrom the command signal by a selected amount.

In accordance with an aspect of the invention, the digital data isstored on the chip of the individual memory buttons; however, inaccordance with an aspect of the invention the memory buttons are merelyloaded with a code. This code inputs digital information from either anethernet network or a memory in the controller for providing the digitaldata to be compared preparatory to enabling the welder to perform thewelding process.

The primary object of the present invention is the provision of A systemfor operating an electric arc welder, which system employs a series ofmanually insertion memory buttons to input the welding process to beperformed, together with various external welding considerations such aswire, gas, prior heat, and weldor qualifications. By inputting thisinformation, the weldor is disqualified from performing the weldingprocess unless the digital data matches to allow operation of thewelder.

Another object of the present invention is the provision of a system, asdefined above, which system employs a series of manually insertablememory chips to enable a welder to perform a welding process defined bya specific welding procedure specification. The specification can beinserted or loaded by any technique, including, but not limited to, amemory button.

Still a further object of the present invention is the provision of asystem, as defined above, which system prevents the welder fromoperating unless the person operating the welder has certainqualifications. In accordance with another object, the qualificationsare updated after each welding process to produce a personal history ofthe operator performing the welding process.

Still a further object of the present invention is the provision of asystem, as defined above, which system has an individual buttoncontaining data or capable of inputting data indicative of the weldingwire characteristics so the welder will perform the welding procedureonly if a proper wire or electrode is being used. In a like manner, amemory chip can be employed which contains data indicative of otherexternal items, such as shielding gas or temperature so the welder willnot operate unless the desired external item is employed with thewelder. In sensing temperature, a touch probe is normally used. Theworkpiece coming to the weld station, such as a robot, may requirepreheating. In that case, a touch probe reads the preheat temperature.In a like manner, the temperature of a bead laid in a multipass weld issensed to determine interpass temperature.

These and other objects and advantages will become apparent from thefollowing description taken together with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic block diagram illustrating the present invention;

FIG. 2 is a schematic block diagram of a modification of theillustration in FIG. 1;

FIG. 3 is a front view of the touch connector with receptacles and aschematic diagram of an operation of features of the invention;

FIG. 4 is a block diagram and wiring diagram of the preferred embodimentof the invention;

FIG. 5 is a block diagram and wiring diagram summarizing the primaryaspects of the present invention;

FIG. 6 is a block diagram and wiring diagram illustrating furtheraspects of the invention; and,

FIG. 7 is a block diagram and wiring diagram of another aspect of theinvention.

Referring now to the drawings wherein the showings are for the purposeof illustrating embodiments of the invention only and not for thepurpose of limiting same, FIG. 1 is a schematic illustration of theinvention. System 10 is used to provide control data by line 12 todetermine the operation of welder A by controller 20. The controller isa standard digital processing device for outputting command signals online 22 to govern the operation of power supply 30, shown as havingpositive terminal 32 and negative terminal 34. Of course, theseterminals can be from a switching network with alternate polarity or canbe from a rectifier to give specific polarity for AC, DC positive, or DCnegative welding. Power supply 30 is not part of the invention and canbe an inverter, down chopper, or other power source architecture. WelderA performs a welding operation at a station schematically illustrated ascontact sleeve 40 for directing current to welding wire or electrode Efrom supply spool 50 toward workpiece W. In some instances, a stickelectrode may be used. Controller 20 causes welder A to perform any of avariety of welding processes involving weld parameters (I_(a), V_(a),WFS), electrical characteristics (AC, DC+, DC−), and other definitionsof the welding mode (pulse, spray, globular, short circuit, STT). System10 includes touch connector 60 in the form of a strip having a series ofreceptacles for memory buttons. Each button has an internal chip loadedwith digital data. Touch connector 60 is shown with several receptacles62-66 for receiving memory buttons 100-106, respectively. The internaldigital chip of each button is loaded with digital informationindicative of certain parameters, as will be explained. Receptacle 62 islocated on touch connector 60 even though it is shown separated becauseof certain intermediate logic processing circuits or programs. Button100 has a chip that contains digital information indicative of thewelding procedure specification WPS. When the button 100 is insertedinto receptacle 62, the information on the internal chip is stored indevice 90 for outputting into system 10. A tag 100 a indicates theparticular WPS carried by button 100. System 10 includes a disablingcircuit 110 which will not allow controller 20 to operate unless anenable output is received from the disabling circuit. To explain theoperation of the disabling circuit, logic gatcs 130 are shown withinputs 112-116 from storage device or memory 90. The welding procedurespecification on the chip of button 100 dictates the parameters ofwelder A, as well as controls disabling circuit 110. The circuits aresoftware implemented, but are shown in hardware format for explanation.

Button 102 in receptacle 64 has a chip with data relating to an externalitem used in welding. In practice, the chip of button 102 containsdigital data indicative of the wire E on spool 50. This data is comparedwith the data on line 112 from button 100. In a like manner, button 104contains data relating to the gas used for shielding the weldingprocess. This data is directed to line 122 for comparison with the dataindicated as line 114 from button 100. The qualification of the personoperating welder A is stored in the chip on button 106. This chipprovides weldor qualification on line 124 for comparison to thequalifications desired as contained in the data on line 116. The use oflines and gates explains the operation of the software used to implementthe invention.

Tags 102 a, 104 a and 106 a are for identification of the items on thechip. For instance, tag 102 a is sent with a spool of wire E. When thespool is loaded onto the welder, the tag is separate so its button 102can be inserted into receptacle 64. Tag 104 a is removed from the gassupply cylinder, while tag 106 is carried by the person to do thewelding. When all the buttons identified by the tags are inserted intotouch connector 60, the welding procedure specification is inputted tocontroller 20 and the individual aspects of the WPS are compared frombuttons 102-106 by circuit 110. If there is coincidence of data betweenthe desired operation of the welding procedure specification and theinformation on buttons 102-106, an enable signal is directed to thecontroller 20 through line 12. This line also inputs other informationrelating to the WPS to be performed by welder A. This data bypasses thedisable circuit 110. Welder A is controlled by parameters from the WPS.If welder A is not capable of performing the desired parameters loadedinto memory button 100, controller 20 does not initiate welding. Theinvention does not relate to the secondary discrimination feature.

By merely inserting buttons 100-106 into the touch connector, theprocess to be performed by welder A is selected and system 10 assuresthat the proper wire or electrode, shielding gas and operator arebrought together for the purposes of successful welding. System 10primarily relates to the coordination of buttons 100-106; however, whenthe other parameters of the WPS are inputted into controller 20, thecontroller also determines whether welder A can perform the desiredwelding operation. Thus, by merely using a series of buttons insertedinto a touch connector, welder A is set to perform the desired weldingoperation and is enabled when the desired coincidence are realized bythe buttons 100-106. Of course, the disable circuit is illustrated inlogic form; however, it is performed by a microprocessor in digitalprogram language.

System 10 a shown in FIG. 2 is a slight modification of the system 10 inFIG. 1. The welding procedure specification loaded into the chip ofmemory button 100 is again received by receptacle 62 to load the desireddigital information in memory 90 for outputting as represented by line92. This information is directed through line 12 into controller 20,except for the portion to be compared by disabling circuit 110 with theinformation to be directed by system 10 a through receptacles 64-68.Disabling circuit 110 has logic gates 130 with first inputs 112-116 fromthe data on the chip of button 100. In this system, buttons 200, 202,204 correspond to the items of buttons 102, 104, 106, respectively, ofFIG. 1. However, the digital data on the chips within these buttonsmerely include an identification code. These codes activate the memory210 to output the actual digital information corresponding to the storedinformation on buttons 102-104 into circuit 110. The coded informationon button 100 causes memory device 210 to output digital informationindicative of the welding wire or electrode E on line 120. In a likemanner, the code on the chip of button 102 causes memory device 210 tooutput the necessary information regarding the shielding gas on line122. The qualifications of the operator can be identified by a code inthe chip of memory button 204. However, in practice, it has been founddifficult to store qualifications at the welder; therefore, in practice,buttons 200, 202 are provided with identification codes for the wire andshielding gas. Actual qualification code is contained in the chip ofbutton 204 for comparison with the desired qualifications of an operatorto perform the specific welding process stored in the chip of button100. The embodiment of FIG. 2 is only a modification of the system 10 toallow the use of identifying codes for memory addresses as opposed tothe actual digital information. In any event, the invention uses amemory button so data is compared to the requirement of the weldingprocedure specification. Preferably, the WPS is on the chip of a memorybutton.

In FIG. 3, a schematic layout of touch connector 60 is illustrated withits receptacles 62-68. The welding procedure specification is outputtedthrough line 222 into a pass-through and discriminating circuit 220.Parameters for the welding process are passed through circuit 220 asindicated by line 224 for storage in register 228. This information iscommunicated by line 230 to controller 20 to govern operation of welderA. In the meantime, the enable line 226 is disabled whenever theinformation on lines 240, 242 or 244 is not consistent with thecorresponding digital data on line 222. Consequently, data on line 230includes the weld parameters, as well as the enable signal for welder Aso it can perform the desired welding procedure specification containedon the chip of button 100. Again, the line drawing depicts softwareimplementation. FIGS. 1-3 are schematic representations of the basicconcept used in the invention. A series of receptacles receive digitalinformation from memory buttons to program a welder for performance of aspecific welding procedure specification. In doing so, certainexternally controlled items or additions are required, such as wire orelectrode, shielding gas and an operator. Additional memory buttons areused to input digital information regarding such items or additions toprevent operation of welder A, except in accordance with the preselectedWPS.

The proposed commercial implementation of the present invention is setforth in FIG. 4. Controller 300 of welder A has input logic so data canbe inputted from buttons 100, 102 and 104 in receptacles 62-68,respectively, of touch connector 60. This data is processed by processcontrol logic 302 that receives the digital data as indicated by lines310, 312, and 314 from interfaces 310 a, 312 a and 314 a, respectively.These interfaces convert the digital data from the chip carried by thebuttons for use by process control logic 302. As so far described,buttons 100 and 106 are inserted into receptacles 62 and 68,respectively, to direct digital data into process control logic 302.This control logic performs the operations as explained in associationwith the schematic representations in FIGS. 1-3. In practice, buttons100, 106 are loaded and buttons 102, 104 are carried by the weldingconsumables, i.e. wire and gas. As shown in FIG. 4, buttons 100, 102 canbe loaded by a web server or computer 320 that stores the many weldprocedure specifications in memory 322 and the qualification of the manyoperators in memory 324. To load the digital data to the chip on button100, a work order selector 330 in computer 320 directs logic by line332. This logic is compared with the welding procedure specifications inmemory 322 available on line 324. The specific work order selects thedesired WPS from line 324 by address device 340. The WPS is thenoutputted on line 342. This digital data is used to program the chip ofbutton 100. In a like manner, button 106 is programmed by the data online 324 a from memory 324. Of course, the buttons are programmed andthen used on touch connector attached to and communicating withcontroller 300. During the welding process, the fact that a specificprocess has been performed is outputted to the WRITE portion of theREAD/WRITE chip of button 106. Therefore, the fact that the operatorperformed a specific welding procedure on a specific date is recorded inthe chip of button 106. This information is then transmitted to computeror web server 320. This is done by connecting button 106 to line 350.This line is not part of the button carried by a proposed operator. Theupdate of memory 324 is normally done by bringing the button back to thecomputer or web server. This new information is then stored in memory352 which stores the history of the various persons performing weldingoperations. Computer 320 uses the new information to update data inmemory 324. Lines 324 a, 342 and 350 are not permanently connected tobuttons 100, 106. They are representative in nature as transmitting ofinformation back and forth from the computer to the button forprogramming or updating.

Control of the information on buttons 100, 106 can be directlyintroduced into controller 300 through an ethernet network 360. In thisinstance, data on line 324 a is communicated through line 362 and thedata on line 342 is communicated through line 364. These lines areinterfaced by network 370 with the process button interface 310 a. Thus,the welding procedure specification WPS is loaded into process controllogic 302 through network interface 370, as indicated by dashed line372. The particular operator qualification and identification isdirected from line 362 into the non-volatile memory 374 where a realtime clock 376 dates and time codes the information for updatingqualifications of the specific operator. The updated information istransmitted back through line 362 and ethernet network 360 to line 380,corresponding with feedback line 350. Thus, data normally inserted bybuttons 100, 106 is processed by the internet, a local ethernet networkor by the buttons. Consumables, such as wire and gas, are alwaysinputted to process control logic 302 by memory buttons 102, 104. Othervariations of button or ethernet communication can be made withoutdeparting from the intended spirit and scope of the invention. However,the invention relates to the use of memory buttons for identifying suchitems as wire and gas.

The welder B shown in FIG. 5 has controller 400 for outputting a normalcommand signal 402 to operate power supply 410 for performing a weldingprocess between electrode or wire E and workpiece W. The electrode isshown as a wire provided by spool 420 through rolls 422 driven by motor424 in accordance with the outputs of microprocessor 426 as determinedby the digital signal on line 428. In accordance with standard practice,current feedback 430 directs a, voltage representing the current. Thisfeedback signal I_(a) appears on line 432. In a like manner, voltagefeedback 440 directs a voltage on line 442 representing the outputvoltage V_(a) across the arc of the welding operation. A wave shapegenerator 450 includes a mode select line 452 for directing thenecessary current or voltage waveform to controller 400 for theoperation of welder B. As so far described, welder B is somewhatstandard and is controlled by a wave shape similar to the Power Wavewelder sold by The Lincoln Electric Company of Cleveland, Ohio. Toassure that the necessary welding procedure specification WPS isperformed by welder B for a specific application, welder B is providedwith novel network 500 including memory buttons 502,504,506,508 and 510.These memory buttons are mounted in receptacles on a touch connector andinclude internal IC chips loaded with appropriate digital data asexplained so far. The process to be performed by welder B is containedin the chip of button 502 which is received in a receptacle to load thedigital data into memory 520. Memory 520 outputs the wire feed speed WFSon line 428 and the wave shape mode on line 452. The rest of theparameters are directed to controller 400 through line 524. In thismanner, as long as the welder is capable of performing the process ofbutton 502, necessary data is entered into the controller and/or theinputs for the wire feed speed and wave shape selector. Digital data inthe chip of button 504 is directed through line 504 a to disable circuit540. In a like manner, the digital data for the shielding gas frombutton 506 is directed through line 506 a to circuit 540. The necessarypreheat or post heat is contained as digital data loaded into the chipof button 510. This information is directed to network or circuit 540 asindicated by line 510 a. The data on lines 504 a, 506 a and 510 a iscompared with corresponding digital data directed to circuit 540 asindicated by line 530. If the digital data corresponds and isappropriate therefor to perform the WPS of button 502, an enable signalis directed by line 550 to gate 552 having an output 554 connected tothe enable terminal of controller 400. Qualifications of the particularoperator for welder B is contained on the chip of button 508. Thus,qualification information is directed by network 562 through line 560 asthe second input of gate 552. Thus, if an appropriate operator isdesignated and the desired wire, gas and heat is being processed,controller 400 operates in accordance with the commands in line 522. Ofcourse, the network is illustrated by logic diagrams; however, they areperformed in practice as software processed by a digital processingdevice in accordance with standard welding technology.

In one aspect of the invention, the WFS is loaded into the logic at theenable portion of controller 400 and only memory buttons 504 and 506 areused. The rest of the WPS is assumed to be met. Also, the WPS can beloaded into the control logic with only button 508 being interrogated.Then the welder is operated normally, but an operator with the neededqualifications must insert his or her personal memory button into theproper receptacle to enable operation of the welder.

Further aspects of the invention are illustrated in FIG. 6 whereincontrol system 600 is associated with the commercial implementationshown in FIG. 4. As represented by block 602, a welding procedurespecification is loaded by a digital interface into section 604 of thecontroller used by the welder. Section 604 uses logic such as networks610, 612 for assuring that specific parameters of the loaded WPS arematched. These logic networks are representative. Network 610 is used toprocess a parameter set by a weldor, such as travel speed inputted atstation 620 of robot 622 and communicated to network 610 as representedby line 624. The WPS has a travel rate that is to be limited between ahigh value and a low value represented by standard high/low circuit 630.The actual travel speed is measured by sensor 632 riding along workpieceW and is communicated to line 624 by way of line 634. Data correspondingto the weldor selected speed from station 620 and to the actual speedsensed by probe 632 are transmitted as digital information to network610. If the selected speed is not proper, comparator 640 activatesdisable circuit 642 to disable the welder. As an alternative, if theselected speed is not proper, circuit 620 will limit the travel speed atcontrol line 650 to a value between the set high and low values. As afurther alternative for concurrent use, the actual feed speed from probe632 will be recorded at block 652 for a history of the weld feed speedduring a weld process. The feed speed can be communicated to section 604by a data entry device 660. The data entry directs data to robot 622 byline 660 a or directly to section 604 or network 612 by alternate line660 b. Another concept of the invention involves a probe 670 to detectan external condition, such as preheat of the workpiece or weld bead.The probed characteristic, such as temperature, is sensed by probe 670which normally touches the workpiece or bead. The data is transmitted tosection 604 as indicated by line 672 and/or to robot 622 by line 674.The sensed data is communicated directly to section 604 or network 612by line 672. This data passes through robot 622 by line 674. The senseddata is process by logic, indicated as gate 680, to compare the sensedcharacteristics with a range forming a feature of the loaded WPS. If thecharacteristic is not within the WPS range, circuit 682 disables thewelder. The logic and circuits shown in FIG. 6 are implemented bysoftware in a digital processing device associated with the controllerof the arc welder.

Another novel use of welding procedure specifications (WPS) is shown ascontrol system 700 of FIG. 7. The weld station or robot utilizing system700 includes a power supply 710 and external drive devices 712, 714.Drive A is for the wire feed speed and drive B is for the travel speedof the robot at the weld station. Power supply 710 receives commandsignal 720 from controller 730. The controller also creates commandsignal 722 for drive A and 724 for drive B. In accordance with standardpractice, the power supply includes a feedback loop 726 for reading theoutput arc current and arc voltage as indicated by line 728. A sectionof the digital processing device of controller 730 is loaded with thewelding procedure specification from storage or memory device 732. Asillustrated, an aspect of the welding procedure specification (WPS) isthe constraints for external conditions, such as arc current, arcvoltage, wire feed speed and travel speed. The logic network 740 isrepresentative process logic for data loaded from memory device 732. Alogic network 740 is provided for each of the external conditions of thewelding operation contained in the welding procedure specification. Onlyone of these logic networks is explained; however, it applies to variousexternal conditions. An operator at the weld station selects the levelof the external condition which set level is communicated to the logicnetwork 740 in controller 730 as indicated by line 750. The command dataon line 750 comes from a data entry station or from the robot as shownin FIG. 6. This selected set level is then processed by a logic networkschematically shown as network 740. This network processes the data seton line 750 as previously described by employing a standard high/lowcircuit 760 by data on input line 762. In this section of network 740,the set level on line 750 is compared with a high and low level in theWPS. If the set level is too high, it is reduced to the high level inoutput line 764. In a like manner, if the selected set level is too low,it is increased to the low level of circuit 760. If the selected levelon line 750 is appropriate under the WPS, it is merely passed through toline 764 through a command portion 770 of network 740. In the situationpreviously described, welder power supply 710 may be disabled when theselected set level on line 750 deviates from the level or valuecontained in memory device 732. This is indicated by disable circuit772. If the set level on line 750 is controlled by circuit 760 or ismerely passed through by circuit 770, network 740 is programmed to allowrecording of the actual processed level. Block 780 is set to record thecondition by select circuit 782 of logic network 740. Thus, the level online 750 actuates logic network 740 to provide an action signal whicheither reduces the set level, passes the set level, or disables thewelder. In instances where appropriate, the action signal also activatesa recording operation for the particular external condition beingprocessed. Of course, other logic networks could be used forimplementing the welding procedure specification in accordance with theset level on line 750. As so far explained, command signals on lines720, 722 and 724 instruct the power supply and the various drives inaccordance with the corresponding parameters from the welding procedurespecification in memory device 732.

During welding, the external conditions are sensed on a real time basis.The arc current and arc voltage are sensed and communicated to controlblock 790 by line 728. In a like manner, the sensed values of externalconditions, such as travel speed and wire feed speed, are communicatedto control block 790 from sensors 792 on line 794. If the system hasbeen set to record for one or more of the external conditions, controlblock 790 records the real time values for external conditions for whichblock 780 has been selected. Control block 790 is in the section ofcontroller 730 receiving data from memory device 732. As indicatedbefore, the welding procedure specification (WPS) loaded from device 732includes values for the various external conditions. A deviation such asthe high and low values in circuit 760 can be tolerated. These same highand low levels for the external conditions are used by block 790 forcomparison with the actual real time conditions from lines 728, 794. Ifthe actual values are improper, control block 790 disables the powersupply 710. Control system 700 is a further aspect of the presentinvention and is performed by software in controller 730 and/or by aprogram and data loaded into the controller through use of memorydevices 732. In accordance with the preferred embodiment of theinvention, memory device 732 is a memory button having a chip loadedwith the digital data indicative of a specific welding procedurespecification. The details of the software are set forth in the blockdiagram and can be varied to accomplish the desired operation for thenovel method and system of the present invention.

The invention involves loading a welding procedure specification (WPS)into a section of the controller used to control the weld process at aweld station. The weld station preferably is a robot combined with theelectric arc welder. By using the present invention, certain items in awelding procedure specification which are not met in the weldingoperation will disable the welder. In practice, these disabling itemsinclude the electrode specification, electrode classification, andelectrode diameter of the wire. These items are loaded into the systemby a memory button having a chip loaded with the data relating to thewire. A wrong wire disables the welder. The welder can be deactivated byan operator selecting the wrong welding process or the wrong electricalcharacteristics, such as polarity. These disabling items of the weldingprocedure specification are sensed by the controller. Data entry orexternal sensors also detect the joint type and the specification of thebase metal. If either of these items do not conform with the weldingprocedure specification, the welder is disabled. As was the case withthe memory button for the welding wire being used in the weld process,the shielding gas, by type and flow rate, is also loaded as data on amemory button. If this gas data is improper, the welder is disabled. Asso far described, items of the welding procedure specification inputtedto the controller either conform with the WPS or the error disables thewelder. These items have been discussed in connection with severalembodiments of the invention.

External conditions as explained in FIG. 7 may disable the welder if setimproperly or are improper during the welding process. These externalconditions are arc current, arc voltage, travel speed, and wire feedspeed. An external condition, such as welding position, which is set bythe operator and then sensed is also an external condition which must beadjusted to be within preselected limits. Travel speed and weldingorientation are conditions and WPS items obtained from external sensorsor feedback from the robot itself. As explained in connection with FIG.6, an external sensor, usually of the touch type, reads the heat of theworkpiece or the heat of a previously created welding bead. This is anexternal condition which can be processed by system 700 shown in FIG. 7.If the temperature of the workpiece is within the high and low level,the welding process can proceed. If it is beyond these limits, this maybe recorded and the welding operation may be disabled. All of theseoperating features of various welding procedure specifications areloaded into the controller and processed to assure that the weldingprocess is within the WPS. Of course, the specification need not includeall of the attributes available in all welding procedure specifications.Other features not so far described could be incorporated in suchspecifications and processed in accordance with the present invention.

Having thus defined the invention, the following is claimed:
 1. A systemfor enabling an electric arc welder having a controller designed toperform various welding processes using weld parameters and a weldingwire comprising a first receptacle for a first memory button having achip loaded with digital data indicative of at least one weldingprocedure specification that includes a set of weld parameters, aspecific weld process, electrical characteristics, and selected weldingwire features; and a circuit to load said at least one welding procedurespecification into controller of said welder to control at least oneoperation of said welder.
 2. The system as defined in claim 1, whereinsaid digital data of said first chip includes digital data definingselected qualifications of the operating welder and including a secondreceptacle for a second memory button having a chip loaded with digitaldata indicative of actual welding qualifications of a welder; and adisable circuit to disable said welder to process said welder procedurespecification when said actual welding qualification fails to fallwithin a predefined deviation of said selected qualifications.
 3. Thesystem as defined in claim 2, including a program to update said digitaldata indicative of at least one actual welding qualification in responseto the processing of said specific welding procedure specification. 4.The system as defined in claim 3, wherein the circuit includes a memoryfor storing said digital data and said first chip includes a coded datato output at least a portion of said digital data into said controller.5. The system as defined in claim 4, wherein digital data at leastpartially from a network and said first chip includes coded data tooutput at least a portion of said digital data into said controller. 6.The system as defined in claim 2, wherein the circuit includes a memoryfor storing said digital data and said first chip includes a coded datato output at least a portion of said digital data into said controller.7. The system as defined in claim 2, wherein digital data at leastpartially from a network and said first chip includes coded data tooutput at least a portion of said digital data into said controller. 8.The system as defined in claim 1, including a program to update saiddigital data indicative of at least one actual welding qualification inresponse to the processing of said specific welding procedurespecification.
 9. The system as defined in claim 1, wherein the circuitincludes a memory for storing said digital data and said first chipincludes a coded data to output at least a portion of said digital datainto said controller.
 10. The system as defined in claim 1, whereindigital data at least partially from a network and said first chipincludes coded data to output at least a portion of said digital datainto said controller.
 11. A system for controlling an electric arcwelder comprising a memory loaded with digital data indicative of aspecific welding procedure specification that includes a set of weldparameters, a controller with a digital processing device having amemory for receiving said digital data and controlling said welder incompliance with said digital data, and a digital reading interface to atleast partially load said digital data from said memory to said sectionof said controller, said memory device is a memory button having an ICchip loaded with said digital data and readable by touch and saidinterface is a touch contactor in a receptacle to touch said memorybutton when said button is placed into said receptacle.
 12. A system forcontrolling an electric arc welder at a weld station comprising acontroller for the power supply and external drives at said weldstation, a data entry station, and a logic network, said controllerhaving a digital processing device including a section to receivedigital data and at least partially control said welder in compliancewith said digital data, said digital data including a selected value foran external weld condition, said data entry station adapted for anoperator to select a level for said external condition, said logicnetwork comparing said selected level and said selected value to createan action signal based upon said comparison.
 13. The system as definedin claim 12, wherein digital data includes a selected welding procedurespecification having a high and low value for external condition. 14.The system as defined in claim 13, wherein said action signal is asignal selected from the group consisting of a command signal settingsaid power supply or external drive to a given value for said externalcondition, a signal recording said condition, a signal to set said powersupply at a value of external condition between a high and a low value,a signal disabling welder when selected level is not within a selecteddeviation from said selected value, and combinations thereof.
 15. Thesystem as defined in claim 13, wherein said external condition is acondition selected from the group consisting of travel speed of anexternal drive, wire feed speed of an external drive, arc current ofsaid power supply, arc voltage of said power supply, and combinationsthereof.
 16. The system as defined in claim 15, wherein said controllergenerates a command signal for said external condition to said powersupply or external drive based upon said welding procedure specificationand said action signal, a sensor to read said external condition on areal time basis, and a circuit to disable said welder when said sensedexternal conditions deviate from said command signal.
 17. The system asdefined in claim 16, wherein said external condition is a conditionselected from the group consisting of travel speed of an external drive,wire feed speed of an external drive, arc current of said power supply,arc voltage of said power supply, and combinations thereof.
 18. Thesystem as defined in claim 13, wherein said data entry station isseparate from said weld station.
 19. The system as defined in claim 13,wherein said weld station is a robot.
 20. The system as defined in claim12, wherein said action signal is a signal selected from the groupconsisting of a command signal setting said power supply or externaldrive to a given value for said external condition, a signal recordingsaid condition, a signal to set said power supply at a value of externalcondition between a high and a low value, a signal disabling welder whenselected level is not within a selected deviation from said selectedvalue, and combinations thereof.
 21. The system as defined in claim 20,wherein said external condition is a condition selected from the groupconsisting of travel speed of an external drive, wire feed speed of anexternal drive, arc current of said power supply, arc voltage of saidpower supply, and combinations thereof.
 22. The system as defined inclaim 21, wherein said controller generates a command signal for saidexternal condition to said power supply or external drive based uponsaid welding procedure specification and said action signal, a sensor toread said external condition on a real time basis, and a circuit todisable said welder when said sensed external conditions deviate fromsaid command signal.
 23. The system as defined in claim 22, wherein saidexternal condition is a condition selected from the group consisting oftravel speed of an external drive, wire feed speed of an external drive,arc current of said power supply, arc voltage of said power supply, andcombinations thereof.
 24. The system as defined in claim 20, whereinsaid external condition is a condition selected from the groupconsisting of travel speed of an external drive, wire feed speed of anexternal drive, arc current of said power supply, arc voltage of saidpower supply, and combinations thereof.
 25. The system as defined inclaim 24, wherein said controller generates a command signal for saidexternal condition to said power supply or external drive based uponsaid welding procedure specification and said action signal, a sensor toread said external condition on a real time basis, and a circuit todisable said welder when said sensed external conditions deviate fromsaid command signal.
 26. The system as defined in claim 25, wherein saidexternal condition is a condition selected from the group consisting oftravel speed of an external drive, wire feed speed of an external drive,arc current of said power supply, arc voltage of said power supply, andcombinations thereof.
 27. The system as defined in claim 26, whereinsaid data entry station is separate from said weld station.
 28. Thesystem as defined in claim 27, wherein said weld station is a robot. 29.The system as defined in claim 12, wherein said external condition is acondition selected from the group consisting of travel speed of anexternal drive, wire feed speed of an external drive, arc current ofsaid power supply, arc voltage of said power supply, and combinationsthereof.
 30. The system as defined in claim 12, wherein said controllergenerates a command signal for said external condition to said powersupply or external drive based upon said welding procedure specificationand said action signal, a sensor to read said external condition on areal time basis, and a circuit to disable said welder when said sensedexternal conditions deviate from said command signal.
 31. The system asdefined in claim 30, wherein said external condition is a conditionselected from the group consisting of travel speed of an external drive,wire feed speed of an external drive, arc current of said power supply,arc voltage of said power supply, and combinations thereof.
 32. Thesystem as defined in claim 12, wherein said data entry station isseparate from said weld station.
 33. The system as defined in claim 12,wherein said weld station is a robot.
 34. A system for controlling anelectric arc welder at a weld station comprising a controller for thepower supply of said welder, a reading device to load control datacontaining a specific welding procedure specification, said controllerhaving a digital processing device with a memory for receiving digitaldata and controlling said welder in compliance with said digital data,said reading device loading said control data into said memory, saidcontrol data including a selected level for an external condition, saidcontroller generating a command signal for said external condition for asensor to read said external condition on a real time basis and acomparator circuit to disable said welder when said external conditiondeviates from said selected level.
 35. The system as defined in claim34, wherein said external condition is a condition selected from thegroup consisting of travel speed of an external drive, wire feed speedof an external drive, arc current of said power supply, arc voltage ofsaid power supply, and combinations thereof.
 36. The system as definedin claim 35, wherein one of said external drives is a wire feeder. 37.The system as defined in claim 36, wherein one of said drives is a robotdrive for travel speed during welding.
 38. The system as defined inclaim 35, wherein one of said drives is a robot drive for travel speedduring welding.
 39. The system as defined in claim 34, wherein one ofsaid external drives is a wire feeder.
 40. The system as defined inclaim 34, wherein one of said drives is a robot drive for travel speedduring welding.